Solution making system and method

ABSTRACT

A solution making system and apparatus are described. The solution maker mixes a chemical or slurry with a solvent to a desired concentration. The concentration of the solution is monitored by one or more methods. Based upon this measurement, the concentration of the solution may be adjusted.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Divisional of U.S. patent application Ser. No.11/996,443, filed Oct. 1, 2008, entitled SOLUTION MAKING SYSTEM ANDMETHOD, which is a '371 of PCT Patent Application, Serial No.PCT/US2006/028951, filed Jul. 27, 2006, entitled SOLUTION MAKING SYSTEMAND METHOD, which is a Continuation-in-Part of U.S. patent applicationSer. No. 11/190,395, filed Jul. 27, 2005, entitled SOLUTION MAKINGSYSTEM AND METHOD, which are hereby incorporated by reference in theirentirety.

TECHNICAL FIELD

Aspects of the present invention relate to an apparatus and method andcontrol system used to produce chemical solutions (for instance, a brinesolution). More specifically, aspects of the invention relate to anapparatus for dissolving a chemical in a solvent to produce a solutionof a specific concentration.

BACKGROUND

Chemicals dissolved in a solvent at a specific concentration are used ina myriad of industries. For example, the application of a salt solutionto reduce the amount of snow and ice from roads, sidewalks, drivewaysand other surfaces is a common industrial practice. Salt solution isgenerally created by mixing rock salt and water to produce a solution.The concentration of the solution may then be adjusted by adding freshwater to dilute the mixture or adding salt to concentrate the mixture. Asolution of approximately 23-27% by weight is efficient for removing iceand snow (where sodium chloride is at least one of the salts). At thisconcentration range, the solution will melt ice and snow with an ambienttemperature of approximately −10 degrees Fahrenheit. If the desiredconcentration is not maintained in the solution and applied in thecorrect amounts on the streets, accidents may occur. For instance, toolittle salt in the mixture may not lower the freezing point of waterbelow the ambient conditions, resulting in a mixture that can promoteicing of roadways as compared to melting previously accumulated ice.

One method of monitoring and adjusting the concentration of a solutionis to measure the specific gravity of the solution and add a solvent(fresh water in the case of some salts) to the solution until a desiredspecific gravity is met. This method thus correlates the specificgravity of the solution with the concentration of the solution. At leastone conventional system provides for producing large quantities ofdissolved rock salt or calcium magnesium acetate (CMA) pellets in waterfor producing a salt solution to be used as a liquid deicer to be usedfor spraying roadways, sidewalks, driveways, and runways to melt snowand ice. An electronic hydrometer (a specific gravity measuring device)measures the specific gravity of the brine/water solution. If thespecific gravity is too high or too low a valve is opened or closed toadjust the amount of fresh water to the mixture. In this manner themixture is adjusted to the salinity desired.

As mentioned above, methods for producing salt solutions that usespecific gravity as an indicator of concentration correlate specificgravity to concentration. This correlation can, in some instances, befaulty. For example, solids such as silica, dirt, and other foreignmaterial in the solution can affect the specific gravity of the solutionand/or the reading of the measuring device. This may in turn lead to anundesired salt concentration level for the solution based onfluctuations in the mixed solution. In addition, measurements based onspecific gravity generally are a series of separate measurements, spacedapart in time and process, rather than a continuous measurement duringthe mixing operation or operations.

Also, other mixing systems are unidirectional and do not account forfluctuations that may occur in mixing operations, thereby providingmixtures that are too low or too high in concentration.

Therefore, there is a need in the art for an apparatus and method thatproduces an accurate concentration level for a mixture.

BRIEF SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features oressential features of the claimed subject matter.

This application discloses an improved system and method for combiningcompounds and/or additives. The system and method described is able toproduce a solution with a desired concentration of chemicals.Alternatively, it could produce a solution with at least a certainconcentration or at most a certain concentration of the chemicals. Thesystem includes an area where the chemicals can be mixed, and aconcentration sensor used to determine if the solution needs to be mademore concentrated or diluted. If the concentration is within a toleranceof the target concentration, solution may be diverted to a storage tankor other vessel.

While multiple embodiments are disclosed, still other embodiments of theinvention will become apparent to those skilled in the art from thefollowing detailed description, which shows and describes illustrativeembodiments of the invention. As will be realized, the invention iscapable of modifications in various obvious aspects, all withoutdeparting from the spirit and scope of the invention. Accordingly, thedrawings and detailed description are to be regarded as illustrative innature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention and the potentialadvantages thereof may be acquired by referring to the followingdescription of illustrative embodiments in consideration of theaccompanying drawings.

FIG. 1 illustrates a perspective view of a solution maker in accordancewith one embodiment of the present invention.

FIG. 2 illustrates a front view of a hopper of an solution maker inaccordance with one embodiment of the present invention.

FIG. 3 illustrates a cutaway front view of a hopper of an solution makerin accordance with one embodiment of the present invention.

FIG. 4 illustrates a cutaway perspective view of a hopper of an solutionmaker in accordance with one embodiment of the present invention.

FIG. 5 illustrates an inside cutaway view of a hopper of an solutionmaker in accordance with one embodiment of the present invention.

FIG. 6 illustrates an interior view of a hopper of an solution maker inaccordance with one embodiment of the present invention.

FIG. 7 illustrates a rear view of a hopper of an solution maker inaccordance with one embodiment of the present invention.

FIG. 8 illustrates an end view of a hopper of an solution maker inaccordance with one embodiment of the present invention.

FIG. 9 illustrates a cutaway end view of a hopper of an solution makerin accordance with one embodiment of the present invention.

FIG. 10 illustrates a grate of an solution maker in accordance with oneembodiment of the present invention.

FIG. 11 illustrates a control panel of an solution maker in accordancewith one embodiment of the present invention.

FIG. 12 illustrates a control panel and mechanical components of ansolution maker in accordance with one embodiment of the presentinvention.

FIG. 13 illustrates a control manifold with programmable logiccontroller and human-machine interface of an solution maker inaccordance with one embodiment of the present invention.

FIG. 14 illustrates flow of an solution maker in accordance with oneembodiment of the present invention.

FIG. 15 illustrates a perspective view of an solution maker and controlpanel in accordance with one embodiment of the present invention.

FIG. 16 illustrates a perspective view of a float assembly in accordancewith one embodiment of the present invention.

FIG. 17 illustrates solvent being added to a first portion of ansolution maker in accordance with one embodiment of the presentinvention.

FIG. 18 illustrates mixing of solvent with chemical in a first portionof an solution maker in accordance with one embodiment of the presentinvention.

FIG. 19 illustrates an inside view of a first portion of an solutionmaker in accordance with one embodiment of the present invention.

FIG. 20 illustrates an inside view of a first portion of an solutionmaker in accordance with one embodiment of the present invention.

FIG. 21 illustrates an inside view of a second portion of an solutionmaker in accordance with one embodiment of the present invention.

FIG. 22 is a flow chart that illustrates the process of making a mixtureof chemicals, slurries, and/or solvents in accordance with aspects ofthe invention.

FIGS. 23A-23C show flow charts that illustrate various methods of mixingadditives into a slurry in accordance with aspects of the invention.

FIG. 24 is a flow chart that illustrates the process of releasing theslurry to another vessel in accordance with aspects of the invention.

FIGS. 25A-25B show various processes for dispensing at least one of asolution and/or mixture in accordance with aspects of the presentinvention.

FIG. 26 shows an alternative solution maker in accordance with aspectsof the present invention.

FIG. 27 shows another alternative solution maker in accordance withaspects of the present invention.

DETAILED DESCRIPTION

The various aspects summarized previously may be embodied in variousforms. The following description shows by way of illustration of variouscombinations and configurations in which the aspects may be practiced.It is understood that the described aspects and/or embodiments aremerely examples, and that other aspects and/or embodiments may beutilized and structural and functional modifications may be made,without departing from the scope of the present disclosure.

It is noted that various connections are set forth between elements inthe following description. It is noted that these connections in generaland, unless specified otherwise, may be direct or indirect and that thisspecification is not intended to be limiting in this respect.

This description is broken into six sections to assist the user inunderstanding aspects of the present invention. The sections include:

a. Solution Maker

b. Additives

c. Dispensing

d. Chemicals, Solutions, and Solvents

e. Modifications

f. Embodiments and Applications

Solution Maker

A solution maker is provided. More specifically, aspects of the presentinvention provide an apparatus and method of producing a solution, suchas a salt solution, with a desired concentration by measuring theconcentration of the solution, determining an amount of solvent to beadded to the solution, and adding the amount of solvent to the solution.Throughout this application the solution, which is any combination of asolvent and a partially or wholly dissolved chemical, may also bereferred to as the slurry. For instance, a highly concentrated mixtureof a salt and a solvent in which less than all of the salt has beendissolved in the solvent may be referred to as a slurry for the purposesof this application. The device may further be configured to separatesediment from the chemical and solvent and flush out depositedsediments. Thus, the device may be configured for separating foreignmaterial such as undissolved silica, dirt, and gravel from the solution.

The solution maker may operate in a manual mode where a user monitors acontrol panel to decide when a concentration of a solution is at adesired concentration. Alternatively, the solution maker may operateautonomously and adjust the concentration level on its own. Further, thesolution maker may operate through a range of operations where someaspects are handled autonomously and others based on the direction of anoperator.

In one embodiment, the solution maker may be configured for producing aclean brine solution by dissolving one or more salts (sodium chloride,for instance) into water or another solvent. In other embodiments, thesolution maker may be used to dissolve other chemicals. Examples includecalcium magnesium acetate, calcium chloride, magnesium chloride,potassium acetate, potassium formate, sodium formate, magnesium acetate,diamonium phosphate, monoamonium phosphate, urea, ethyl glycol,propylene glycol, and other chemicals. The solution maker may produce asolution having a concentration of a desired target concentration, adesired target concentration range, or equal to or greater than a targetconcentration. The solution maker can also dilute solutions or slurriesthat have already been produced.

As shown in FIGS. 1 through 3, one aspect of an solution maker 100 mayinclude a mixer 102 having a first container 104 and a second container106. An example suitable capacity for the mixer 102 is five cubic yards.The first container 104 and the second container 106 are separated by agrate 142. The first container 104 is adapted to receive a chemical fordissolution in a solvent to produce a solution. To produce a brinesolution, the component may be, for example, sodium chloride (NaCl orsalt) or calcium magnesium sulfate. The chemical may be provided in anysuitable form. For example, if the chemical is salt, it may be providedin pellet or rock form. Other components may be used to produce othersolutions. As will be described more fully below, the solution maker maybe calibrated for use with different chemicals or solvents to producedifferent solutions. In one embodiment, the solution maker mixes sodiumchloride and fresh water to produce a brine solution. The chemical inthe first portion may provide a chemical bed. For example, in producinga brine solution, a salt bed may be formed in the first container 104.

The first container 104 is further adapted to receive a solvent formixture with the chemical to produce the desired solution. The variouscomponents of the brine maker may be downward flowing and the solventpasses through the chemical bed in the first container 104 due to theforce of gravity. The solvent may be delivered to the first container104 in any suitable manner. A solvent line leading to the mixer 102 maybe provided. An optional, self-regulating heating element may be coupledto the solvent line to protect against freezing of the solvent. In theembodiment of FIG. 1, the solvent is delivered via a solvent valve 136that actuates flow from a solvent inlet 138. The solvent valve 136 maybe provided as an electric actuated valve and valve actuation may becontrolled by controller such as a programmable logic controller (PLC)216 (see FIG. 12). Although many types of controllers could be used, theterm PLC is used for simplicity in describing the controller in variousaspects of the invention. Actuation of the valve may depend on one ormore liquid level sensors and/or may be controlled by an operator orsome combination of automatic operation and operator control. Asdescribed more fully below and shown in FIG. 3, a first liquid levelsensor 118, a second liquid level sensor 120, and a third liquid levelsensor 122 may be provided. As shown in FIGS. 8, 12, and 19, in aspecific embodiment, the solvent inlet 138 may be pressurized and maysupply solvent to the solution maker 100 via a solvent valve 136,conduit 200, manual valve 186, manual valve 158, conduit 176 and sprayhead 178 to dilute valve 134. The fresh solvent valve 136 may furtherinclude a manual override. Of course, while a specific configuration isherein described, an solution maker within the scope of the presentinvention may include fewer or more component parts as would beunderstood by one skilled in the art.

A grate 142 substantially prevents the chemical from passing from thefirst container 104 of the mixer 102 to the second container 106 of themixer 102 before the chemical is dissolved in the solvent. Perforationsmay be provided in the grate 142. When a solution comprising the solventand dissolved chemical is formed in the first container 104, theperforations in the grate 142 allow the solution to pass through thegrate 142 into the second container 106 of the mixer 102. FIG. 5illustrates one embodiment of a grate 142 suitable for use with thesolution maker. As shown, the grate 142 may include a plurality ofannular perforations 143. The perforations 143 may be approximately 3/16inch diameter. Desirably, the perforations 143 are large enough topermit even flow of the solution through the grate 142 but small enoughto prevent the chemical from passing through the grate 142. Thus, thegrate 142 operates to support the chemical, collect debris, and allowpassage of solution. In one aspect, the grate 142 is nonmetallic andincludes 1½ inch fiberglass structural cross members.

FIGS. 19 and 20 show the inside of a first container 104 of a solutionmaker. In FIG. 19, spray heads 178 for expelling solvent and grate 142may be seen. FIG. 20 shows flow through the spray heads 178.

As stated above, one or more liquid level sensors may be provided. Theliquid level sensors are liquid level sensing devices. They may beprovided with switches that send a signal to the PLC 216. As such, theliquid level sensors may be operably connected to inputs of the PLC 216.The liquid level sensors may be provided as any suitable device. In oneembodiment, a suitable liquid level sensor is a mechanical switch with afloat device that activates a micro switch. In another embodiment, aninductive capacitive proximity switch may be used. The liquid levelsensors maintain liquid levels in the mixer 102, and more specificallyin the first portion of the mixer 102, at a desired level. Generally,high water levels may overfill the mixer 102 and create a spill whilelow water levels may cause a transfer pump 124 to run dry and therebydamage the pump seals.

As shown in FIG. 3, first, second, and third liquid level sensors 118,120, and 122, respectively, are provided. Reference is made to FIGS. 7and 9 to further illustrate the liquid level sensors. In someembodiments, more than three liquid level sensors may be provided.Alternately, no liquid level sensors may be provided. The first liquidlevel sensor 118 abuts the mixer 102 and is generally adjacent to thesecond liquid level sensor 120 and may be connected to an input of thePLC 216. The first liquid level sensor 118 detects if the water level inmixer 102 is low. If the liquid level is low and the solution maker 100is in run mode, a pump 124 is turned to an “off” state if the solutionmaker 100 is in run mode. This protects pump 124 from damage caused byrunning dry.

The second liquid level sensor 120 is generally adjacent to the firstliquid level sensor 118 and the third liquid level sensor 122 and may beconnected to an input of the PLC 216. The second liquid level sensor 120detects if an adequate amount of water or other solvent is present inthe mixer 102. Based on the detection of an adequate amount of solvent,the pump 124 is activated and switched to an “on” state. The pump 124 islatched into the “on” state until the batch is completed or the firstliquid level sensor 118 detects that the liquid level is low.

The third liquid level sensor 122 abuts the mixer 102 and is generallyadjacent to the second liquid level sensor 120 and may be connected toan input of the PLC 216. The third liquid level sensor 122 detects ifthe mixer 102 is holding a predetermined level of liquid. If this levelof liquid is sensed, the solvent valve 136 is switched into the “off”position, thus protecting the mixer 102 from overflowing.

The second container 106 of the mixer 102 includes a brine solutionsuction tube 164 connected to a conduit 148 and a brine outlet valve154. The brine outlet valve 154 is connected to the transfer pump 124via an outlet conduit 148. A solvent dilute inlet 146 and a pump suctioninlet may be connected to the conduit 148. As shown, the pump 124 may beprovided in communication with a solution sensor 132.

The solution sensor 132, in one example, measures the concentration ofchemicals in the solution. In one aspect, the sensor is a conductivitysensor. For example, it could be a conductivity sensor of the terodialtype, which is solid state with no contact points and measures theinductive field of the solution. However, many conductivity sensors areknown in the art. In another aspect, the solution sensor 132 may be arefractometer. The refractive properties of the solution vary based onconcentration. The refractometer detects the refractive index of thesolution, and the PLC 216 then is able to calculate, and adjust, theconcentration reading as appropriate. In other aspects, a hydrometer orother device used to detect the specific gravity of the solution couldbe used as solution sensor 132.

The solution sensor 132 may be configured to measure continuously, thusproviding constant input rather than periodic snapshots to the PLC 216,thereby increasing the efficiency of the machine.

Alternatively, a refractometer can be used in place of the solutionsensor 132. The refractive properties of the solution vary base onconcentration. The refractometer detects the refractive index of thesolution, and the PLC 216 then is able to calculate, and adjust, theconcentration as appropriate.

In another aspect, the solution sensor 132 may be combined with atemperature sensor. This may be desirable because, in the case of thesolution sensor being a conductivity sensor, the electrical resistanceof the solution may vary with temperature as well as concentration. Thereading from the solution sensor and the temperature sensor would beused to form a temperature compensated conductivity reading. Thisreading could be equated to a concentration curve which in turnexpresses the reading of the solution as a temperature compensatedconcentration by weight. A concentration curve correlating temperaturecompensated conductivity to concentration may be developed for anychemicals in solution. Thus, for example, in a brine maker, a sodiumchloride concentration curve is used. As stated above, in one aspect,the solution sensor measures the temperature and the conductivity of thesolution. The properties of brine change with temperature and, thus, itmay be desirable to measure the temperature to formulate the actualconcentration.

Alternatively, the solution sensor 132 could operate without the aid ofa temperature sensor. This could be desirable because the solutionsensor directly measures a property that does not vary with temperature.It could also be desirable because it is less costly and lesscomplicated to operate without sensing the temperature.

As will be described more fully below, solution that is outside of atolerance of a target concentration may be adjusted while solution thatis within a tolerance of a target concentration may be processed to astorage tank. By measuring and adjusting the concentration midstream,the solution maker produces solution continuously at a targetconcentration without the intervention of an operator.

With reference to FIGS. 1, 12, and 13, the solution sensor 132 may be inoperable communication with the PLC 216. In response to the determinedconcentration, the PLC 216 may activate a dilute valve 134 or a divertervalve 130 to ensure that only solution of a desired concentration isdiverted to a storage tank. The target concentration of the solution maybe any desired concentration. For brine solutions, a suitable targetconcentration may be in the range of 19.6 to 27% by weight. For example,the target concentration may be 23.3% by weight. In addition toestablishing a desired solution concentration, a desired solutionconcentration tolerance may be established wherein a certain variancefrom the desired solution concentration is considered acceptable. Anacceptable tolerance may be +/−0.3% of the target concentration.

The diverter valve 130 diverts flow from the pump 124 through a returntube 126 if the solution concentration is above or below the targetconcentration or through a finished product tube 128 if the solutionconcentration is within the approximately the desired solutionconcentration. The diverter valve 130 may be controlled by the PLC 216(and/or by an operator or combination thereof) and depends on the targetversus actual concentration. Solution that is outside of a tolerance ofthe target concentration may be diverted to conduit 126, valve 156,conduit 180, and agitation nozzles 166 for a further pass through themixer 102. Again, while a specific embodiment of a diverting mechanismis provided, alternate mechanisms as would be known to one skilled inthe art may be used for diverting solution outside of a tolerance of atarget concentration or range of target concentrations to the mixer 102.

The return tube 126 passes flow to a valve 156, a conduit 180 andagitation nozzles 166 in the first container 104 of the mixer 102. Thesolution passes through the return tube 126 and returns to the mixer102. The finished product tube 128 passes to a storage tank 410 (seeFIG. 14). The diverter valve 136 may further include a manual override.

The dilute valve 134 is controlled by the PLC 216. The dilute valve 134may communicate with the solution pump 124. The dilute valve 134 thusactuates open to pass sufficient solvent to dilute the solution whenpump 124 is passing flow and the solution sensor 132 senses a solutionactual concentration over the target concentration. The dilute valve 134communicates with the solvent inlet 138. The dilute valve 134 actuatesopen when the pump 124 is passing flow and the solution sensor 132senses a solution actual concentration over a target concentration. Whendilute valve 134 is open, solvent from the solvent inlet 138 passesthrough the dilute valve 134 into the conduit 212 and into the diluteinlet 146. The solvent combines with the solution passing from thesecond container 106 of the mixer 102 to the pump 124. The dilute valve134 allows sufficient solution to dilute the over-concentrated solutionreaches the target concentration and thus does not over-dilute thesolution. The dilute valve 134 may further include a manual override.

The sensed solution may be diluted in any suitable manner at anysuitable point. For instance, the sensed solution may be diluted viaaddition of solvent to the outlet tube. Alternately, the sensed solutionmay be diluted via return to the mixer 102 and mixing with furthersolvent in the mixer 102.

A flow measuring device 204, shown in FIG. 12, may be provided formeasuring the volume of finished solution being transferred to thestorage tank. The flow measuring device 204 may be provided incommunication with the PLC 216. Further, an additive pump 210, flowmeasuring device 206, and actuated valve 208 may be provided to allowflow into a conduit 128. The additive pump 210, flow measuring device206, and actuated valve 208 may be in communication with the PLC 216 toenable mixing of an additive with the solution as it is transferred to astorage tank, as is described more fully below.

During use, solids such as dirt and silica may infiltrate the solutionmaker. These solids typically cause sediment build up in solution makingmachines. Generally, it is desirable for the solution to be as clean aspossible. Foreign material in the solution is abrasive. The abrasivenesscan produce excess wear on pumps, flow meters and valves associated withthe production and application of the brine solution. Sediment depositscaused by foreign material in suspension of the solution over timesettle out and form layers of sediment in the storage tank. Cleaning thesediment can be time consuming and can require the machine to beoffline.

In one embodiment, the second container 106 of the mixer 102 isconfigured for easy cleaning. The second container 106 (see, forexample, FIGS. 3 and 21) thus includes at least one sloped plane alongwhich sediment slides to a sump located at the bottom of the slopedplane. A suitable slope for the at least one sloped plane isapproximately 15 degrees. In the embodiment shown, the second container106 includes a first sloped plane 150, a second sloped plane 152, and athird sloped plain 202. Sediment that passes through the grate 142collects on the bottom of the second container 106 of the mixer 102 in asump area formed by the first sloped plane 150, second sloped plane 152,and the third sloped plane 202. The sump area may be, for example,approximately 12 inches by 12 inches. Other coatings that allow easycleaning are well known to those of ordinary skill in the art.

A sump outlet 108 may be provided to allow the sediment to be flushedout of the mixer 102. Such flushing may be done via spray bars 402(shown, for example, in FIGS. 2 and 9) and a nozzle 162 (shown, forexample, in FIG. 3). A plurality of nozzles, for example a nozzleprovided on each wall to the left, right, and back side of the sump, maybe provided for forcing sediment through the sump and out of thesolution maker. The solution maker may be configured for flushing of thesediment or for manual flushing of the sediment. Further, the sedimentmay be flushed from the mixer 102 while the chemical is in the firstcontainer 104 of the mixer 102 or may be flushed from the mixer 102 whenthere is substantially no chemical present in the first container 104 ofthe mixer 102. The grate 142 in the mixer 102 supports the weight of thechemical, thus enabling the sediment to be flushed while the chemical isin the mixer 102.

Thus, the solution maker further provides a method for separatingforeign material such as un-dissolved silica, dirt, and gravel from themixer 102. The foreign material may accumulate in a sump area from whichthe deposits may be flushed at a later time. Further, the solution makerenables a flushing of deposits of foreign material from the mixer 102while a chemical remains in the first portion of the mixer 102.

In another embodiment, the solution maker may lack a cleanout system asdescribed above. In this alternate embodiment, a mixer 102 may be usedwith less manufacturing, thereby providing cost savings in environmentswhere cleaning the mixer 102 is either not needed or where cleaning themixer 102 on a regular basis is not required. Here, systems that do notaccumulate debris or are relatively clean may be used with a mixer 102without a cleanout.

The solution maker, in some embodiments, may hold 10,000-20,000 poundsof a chemical such as salt. Thus, the mixer 102 is manufactured to besufficiently strong to support the load. The mixer 102 may be made ofany suitable material. In one embodiment, a suitable material from whichthe mixer 102 may be constructed is fiberglass. Fiberglass is strong andis not affected by salt solutions. More specifically, the mixer 102 maybe constructed of 16,000 lb tensile strength fiberglass and isophthalicresin. Other suitable materials for the mixer 102 include but are notlimited to stainless steel and polypropylene. The inside surfaces of themixer 102 may be coated with a ceramic resin. Such coating may be, forexample, approximately 0.050 inches thick. Structural integral ribs maybe provided within the mixer 102 to limit flex to within one inch fromfull to empty. In one embodiment, the overall thickness of fiberglassand resin in the mixer 102 is approximately 0.35 inches. Structuralareas such as ribs, corners, and floor may be provided with additionallayers of woven fiberglass mat for an overall thickness of approximately0.50 inches.

In use, the solution maker may be used by a highway department forproducing brine solution to deice roads. The solution maker may be usedoutdoors in cold weather. Thus, the solution maker may be provided withone or more of its components being heated. Heating elements 168 (see,for example, FIG. 3) may be provided in the mixer 102. A temperaturesensing device may be provided in the mixer 102 in communication withthe PLC 216. The temperature sensing device indicates if the heatingelements 168 need to be activated to raise the temperature of the mixer102. These elements may be thermostatically activated on and off andcapable of sustaining a temperature of 32 degrees Fahrenheit or higherto prevent the vessel from freezing.

Thus, the mixer 102 may be heated to minimize the chance of the mixer102 freezing in cold weather. In one embodiment, silicone mat heatersmay be built into the mixer 102. For example, two nine-foot squaresilicone mats may built into the mixer 102. A roll tarp such as apermanently mounted roll tarp may be used in conjunction with theheaters for heating the mixer 102. Such roll tarp may be provided witharches and a roll mechanism and is useful for keeping heat in and debrisout. If provided, the roll tarp may be mounted over an open top of themixer 102. Other heating methods are well known to others of ordinaryskill in the art.

FIGS. 11-13 illustrates embodiments of a control panel of the solutionmaker. The control panel 500 may be included of mechanical flow controldevices, the conductivity sensor 132, the PLC 216, and the human-machineinterface (HMI) 214. In another embodiment, the PLC 216 is incommunication with HMI 214 to create a data log. Solution produced anddiverted to the storage tank is measured via a flow measuring device 204(see, for example, FIG. 12) and recorded in the PLC program 216. Thismeasurement may be via a flow meter of a flow switch. Calculations maybe introduced into the PLC program 216 to formulate the amount ofsolution produced, the chemical usage, and the solvent usage in theproduction process. The data log thus creates reports that may be viewedon the HMI 214 or printed onto a printer. These reports may be createddaily and may show a running season total of solution produced as wellas chemical and solvent usage (and additive usage if an additive isintroduced into the solution). Multiple user reports may be generated.For example, a daily and season total may be created and tailored forseparate individuals for accounting and billing purposes.

The control panel 500 may include one or more processors that controlthe operation of the control panel. The control panel 500 may alsoinclude internal memory including at least one of solid state (RAM, ROM,Flash, magnetic, and the like) and dynamic memory (CD, DVD, Hard Drive,etc.). The control panel may have no or various input/output pathwaysincluding but not limited to wired (for instance, USB, Firewire, andother wired pathways), wireless (for instance, IEEE 802.11*, Wi-Max,cellular, satellite, RF, Bluetooth, and other wireless pathways), andmedia-related interfaces (for instance, CD, DVD, and other media-relatedinterfaces). The control panel 500 may optionally include the ability toconnect to a network or other devices including the internet. Further,the control panel 500 may optionally include a location determinationsystem (including but not limited to cellular, satellite, and the like).The location determination system may provide information that allowsthe location of the control panel 500 to be communicated to anotherdevice or network. Further, the control panel 500 may be able to usethis information in modifying desired concentrations, additive mixing,and the like, based on the determined location. For instance, thecontrol panel 500 may provide more additives based on one locationcompared to less additives based on another location. Alternatively, itmay be provided its location based on user input or a locationtransmitted to it remotely.

In one example, the PLC 216 may handle operations independent of the HMI214. In other situations, the PLC 216 may be replaced by the HMI 214alone. Further, the PLC may be networked with other computers orcomputing systems thereby allowing communication between them and/ordownloading of new information to the PLC 216. For instance, a centralcommand center may instruct PLC 216s in various locations to increasethe use of one chemical/solvent/solute/slurry compared to another. Also,the networking of the PLCs 216 (for example, to the internet or othernetwork) may allow firmware updates or data uploads regarding usage andother metrics. Further, data keeping functions may provide reports orrequests to the network for data keeping and/or ordering of morematerials.

Yet further, the networking of the PLCs 216 may allow remote operationof the system. For instance, one may operate one HMI to control two ormore mixers 102.

The reports may additionally provide a quantitative measurement ofsolution or other output produced and/or time needed to make thesolutions or other mixtures. These reports may be output in one or moreforms including forms appropriate for storage in a database (SQL,Microsoft Access, and the like).

The control panel enables regulation of solvent flow into the firstportion of the mixer 102. The solvent concentration and/or actualtemperature compensated concentration may be monitored and, if theconcentration is out of the tolerance for the target concentration, thesolution may be returned to the mixer 102. Alternately, the solution maybe diluted mid-stream after exiting the mixer 102 to meet the desiredconcentration level. Solution of a desired concentration may beprocessed to a holding tank. As shown, the PLC, conductivity analyzer,and other electric controls may be mounted in an electric enclosure onthe rear side of the panel. The main panel of the control panel mayinclude valve labels and valve functions. Information displayed on thescreen may include the actual production solution concentration in theform of % concentration by weight, the gallons of solvent used to makesolution, self-diagnostic of the conductivity sensor, self-diagnostic ofelectric valves (indicating if and what valve is not functioningnormally), valve status of open or closed, and status of the machinealong with the status of electrical components. In one embodiment, thedisplay is multicolored with a green screen indicating system normal, ared screen indicating machine fault, and an orange screen indicatingsetup parameters.

The holding tank or tanks may be filled individually or filled in anorder specified by the control panel or HMI. For instance, a firstholding tank may be designated as the location for the output of thesolution maker 100 or mixer 102. Next, another tank may be filled afterthe first holding tank is full (based on a predetermined amount ofsolution dispensed or a sensor on the tank). The control panel may beprogrammed to fill a number of tanks then stop the dispensing and/ormixing process.

The solution maker may be configured as self-diagnostic. Accordingly,the valves and sensors may be in operable communication with thecontroller to confirm the current state. In the event of a componentfailure, the system may be configured to shut down and provideinformation on the specific failure along with a corrective measure,including how to manually override problem and part number failure.

FIG. 14 illustrates flow of an solution maker in accordance with oneembodiment of the present invention. As shown, solvent 402, such aswater, passes into the mixer 102 404. In the mixer 102 404, the solventmixes with a chemical, such as salt, to form a solution, such as brine.The solution 406 exits the mixer 102 404. A conductivity sensor 408measures the conductivity of the exiting solution 406 and therebydetermines the concentration of the solution 406. If the concentrationis within the desired range, the solution 406 continues to a storagetank 410. If desired, an additive 412 may be added to the solution 406after it is determined to be at an acceptable concentration. If thesolution 406 is not at the desired concentration, it is returned 414 tothe mixer 102 404. This process is described more precisely below.

In operation, a chemical, for example rock salt, is deposited in thefirst container 104 of mixer 102. The pump 124 is initially in the “off”state while the solvent valve 136 is in the “on” position. An operatorat the HMI 214 enters a desired target solution concentration, volume ofsolution to be produced, and, if desired, a ratio of additive in thefinished product. Upon entering this information, the operator activatesa start switch which activates the PLC program into the operation mode.The operation mode begins solvent flow from valve 136 into the mixer 102104. The first container 104 of the mixer 102 receives solvent fromspray heads 178 via the solvent inlet 138, the actuated valve 136, theconduit 200, the valve 186, the valve 158, and the conduit 176. Thesolvent dissolves the chemical, and the formed solution passes throughthe grate 142 into the second container 106 of the mixer 102. Solventcontinues to enter through the spray heads 178 into the mixer 102 untilthe third liquid level sensor 122 detects the mixer 102 is full ofliquid and activates the solvent valve 136 into the “off” position sothat the mixer 102 does not overflow.

While the mixer 102 receives solvent, the second liquid level sensor 120detects whether an adequate amount of solvent is present in the mixer102. When an adequate amount of solvent is present in the mixer 102, thepump 124 is actuated into an “on” position. The pump 124 is latched intothe “on” position until the batch is completed or the first liquid levelsensor 118 detects that the liquid level is low.

The pump 124 transfers the solution from the second container 106 ofmixer 102 through the first suction tube 164, the conduit 188, the valve154, conduit, dilute inlet 146 and into the suction side inlet of thepump 124. The pump 124 may be configured to pump approximately 5,000gallons of solution per hour with a dynamic head of 45 feet.

The solution sensor 132 senses the conductivity and the temperature ofthe solution transferred by the pump 124 from the mixer 102 106. Thesolution sensor 132 measures the electrical resistance of the solutionflowing across the solution sensor 132. This measurement may be done bya probe and conductivity analyzer of the solution sensor 132. Theelectrical resistance is compared to the temperature of the solution andthese two variables are equated to form a temperature compensatedconductivity reading. This reading is equated to a chemicalconcentration curve which in turn expresses the reading of the solutionas a temperature compensated concentration by weight. A concentrationcurve correlating temperature compensated conductivity to concentrationmay be developed for any chemicals in solution. Thus, for example, in anbrine maker, a sodium chloride (and/or other salt) concentration curveis used.

If the solution is over-concentrated the conductivity analyzer, thencommunicates with the PLC 216, which in turn opens the dilute valve 134to permit solvent to dilute the over-concentrated solution exiting themixer 102 106 to the target concentration. When the dilute valve 134 isactivated, solvent from the solvent inlet 138 passes through the dilutevalve 134 and into the dilute inlet 146 and combines with the solutionpassing from the second container 106 of the mixer 102 to the pump 124.The dilute valve 134 remains activated until the solution reaches thetarget concentration. The over-concentrated solution is diverted fromthe pump 124 by the diverter valve 130 and passes through the returntube 126 into the first container 104 of the mixer 102 via the conduit180, valve 156 and agitation nozzles 166.

If the solution is under-concentrated, the under-concentrated solutionis diverted from the pump 124 by the diverter valve 130 and passesthrough the return tube 126 into the first container 104 of the mixer102 via valve 156, conduit 180, and agitation nozzles 166.

If the solution is within a tolerance level of a target concentration,the solution is diverted from the pump 124 by the diverter valve 130 andpasses through the finished product tube 128 and into a storage tank(not shown). Optionally, if trucks are being loaded with solution duringoperation of the solution maker, solution within a tolerance level of atarget concentration may be diverted directly to the a truck via a truckfill hose. When diverting solution to a storage tank, a remove tillelectric plug wiring harness may be provided to shut off filling of thestorage tank when full. Thus, a sensing device may be provided forsensing the state of the storage tank.

Over time the liquid level drops in the mixer 102 due to solution withinthe tolerance level of the target concentration being sent to thestorage tank. First liquid level sensor 118 detects if the water levelin mixer 102 is low and turns pump 124 to the “off” state if thesolution maker 100 is in operate mode. Alternately, solvent andchemicals may be continuously provided to the solution maker. In asemi-continuous embodiment, the solution maker 100 continuously producessolution of a desired concentration. Thus, the solution maker 100 may beconfigured for continuous batch processing. Continuous batch processingenables production of more solution per amount of time the solutionmaker is running.

The configuration of the solution maker thus offers a downward flowdesign. In the first container 104 of the mixer 102, solvent flowsdownwardly through the chemical to form the solution. Upward flow designis well known in the art but would also include pumps to counteractgravitational forces, which assist the downward flow design. It isappreciated that aspects described herein include both upward anddownward flow designs.

The solution passes through the grate 142, into the second container106. The solution with the highest concentration settles to the bottomof the second container 106 where the solution is removed forprocessing.

A data log may be generated by the solution maker for recording how muchsolution is produced and the quantity of ingredients (chemical andsolvent) used.

FIGS. 3, 5, and 20 further illustrate the easy cleaning aspect of thesolution maker.

FIGS. 3, 5, and 21 illustrate the sloping surfaces and sump of thesecond container 106 of the mixer 102. Due to the sloping surfaces,sediment that passes through the grate 142 collects on the bottom of thesecond portion in an area adjacent a sump outlet 108. Any suitablenumber of sloping surfaces may be used. In the embodiment shown, a firstsloped plane 150, a second sloped plane 152 and a third sloped plain 202are provided. Thus, sediment that passes through the grate 142 collectson the bottom of the second container 106 of the mixer 102 in an areaformed by the first sloped plane 150, the second sloped plane 152 andthe third sloped plane 202. The sump outlet 108 allows the sediment tobe flushed from the mixer 102 using the spray bars 402 and nozzles 162,as described above.

FIGS. 2-4 illustrate the mixer 102. The mixer 102 includes a firstcontainer 104 and a second container 106. Nozzles 162 are provided onthe second container 106. The nozzles 162 spray a liquid substantiallyin the direction of sump outlet 108, provided in the second container106. In one embodiment, the liquid that is sprayed by the nozzles 162 iswater. Thus, liquid is expelled from the nozzles 162 and directedtowards sediment accumulated adjacent the sump outlet 108. Force fromthe spray forces the sediment to pass through the sump outlet 108. Ofcourse, any other suitable means for forcing the sediment through thesump outlet may be used.

As further illustrated by FIGS. 19 and 20, the first container 104 ofthe mixer 102 may include a spray head 178. Alternately, the firstcontainer 104 may include a plurality of spray heads. The spray head 178receives solvent from the solvent inlet 138 via the solvent valve 136.

FIGS. 6 and 9 illustrate a plurality of spray bars 402 (only one sideshown) that are located on opposite sides of second container 106 of themixer 102. The spray bars 402 spray a liquid that forces sedimenttowards the sump outlet 108.

As described above, during use of the solution maker, sediment may passthrough the grate 142 into the second container 106 of the mixer 102.Sediment that settles on first sloped plane 150 and second sloped plane152 is forced downward towards the bottom of second container 106 viaspray bars 402 that are positioned along the first sloped plane 150 andthe second sloped plane 152. The spray bars 402 are supplied with liquidvia liquid supply 138, conduit 200, water inlet 186, flush valve 160,and conduit 174. The sediment that is located in the bottom of secondcontainer 106 is forced out of the sump outlet 108 of the secondcontainer 106 via the nozzle 162. Liquid is supplied to the nozzle 162via liquid supply 138, conduit 200, water inlet 162, and conduit 172.

The chemical is supported within the first container 104 by the grate142. Thus, the sediment may be flushed from the mixer 102 while chemicalis in the first container 104 of the mixer 102. Alternately, thesediment may be flushed from the mixer 102 when there is substantiallyno chemical in the first container 104 of the mixer 102.

FIG. 12 illustrates a control panel for an solution maker wherein anadditive may be supplied to the solution. Thus, the solution maker maybe used to inject an additive into the desired solution concentration ata desired ratio. For example, when the solution maker is used to makebrine, additives that make brine work at lower temperatures or reducethe corrosiveness of brine may be beneficial.

Typically brine is used at approximately 20 degrees Fahrenheit or above.By mixing additives with the brine, the effective temperature for usingbrine may be reduced to approximately 0 degrees Fahrenheit, therebyproviding a solution of melting snow and ice at lower temperatures. Saltbrine is naturally corrosive and the corrosive nature of the brine leadsto corrosion of bridge decks, vehicles, and roadways. Reducing thecorrosive nature of brine and lowering the freezing point of brine bymixing at least one additive at a predefined ratio into the brine hasbenefits to the environment. Generally, these additives are costlycompared to the cost of brine solution. Optionally, a system may includethe ability to add a desired amount of additive into the solution whenneeded and thus reduce cost and enable an enriched product to beproduced when needed.

Using the embodiment of FIG. 12, a user enters a desired percentage oftotal volume in which an additive is to be processed via the HMI 214 tothe storage tank where the finished product is stored. As brine isproduced and diverted to the storage tank, a predetermined ratio ofadditive is placed into the conduit 128 via the pump 210 controlled bythe PLC 216 connected to a supply tank for the additive (not shown). Thepump 210 transports the solution. A flow meter 206 is in communicationwith the PLC 216 and measures the additive volume. An actuated valve toshut off flow is controlled by the PLC 216.

Thus, in the embodiment shown in FIG. 12, a solution may be produced atdesired concentrations and, as the solution is transported to a holdingtank, a desired ratio of additive based on volume of solution may bemixed with the solution. This ratio may be between 0 and 100%, asdesired. The solution maker thus produces brine and has the ability tomix and inject any ratio of additive into the solution.

FIG. 16 illustrates a perspective view of the float assembly on themixer 102.

FIG. 17 illustrates solvent being added to a first container 104 of ansolution maker via spray heads 178.

FIG. 18 illustrates mixing of the solvent with the bulk chemical in thefirst container 104 of the solution maker.

FIG. 19 shows first container 104 with spray head 178 over grate 142before any bulk chemical has been added to the first container 104.

FIG. 20 shows first container 104 being sprayed with a solvent fromspray head 178 over a bulk material.

FIG. 21 shows second container 106 with first sloping plain 150 andthird slipping plane 202 showing a solution having been created andflowing toward brine outlet valve 154.

FIGS. 22-25B show various processes that may be used in conjunction withthe solution maker 100 and additional components.

FIG. 22 illustrates the process of creating a mixture of solutes andsolvents. Although a single solute and a single solvent are oftencombined to make a slurry, the aspects of the invention are not solimited. Multiple solutes and solvents can be made into a slurry. Forexample, solvent 2201 and solvent 2202 are combined with solid chemical2203 and solid chemical 2204 to produce a new slurry 2206 in FIG. 22.Although solid chemicals are used in this illustration, liquids can alsobe used. For example, slurry 2205 can also be added to solvents 2201 and2202 to produce slurry 2206. In the case that slurry 2205 is the onlychemical being added to the solvents, the solution maker would functionas an dilution machine.

As described above, the solution maker can be used to ensure slurry 2206is at, above, or below a desired concentration. In step 2208, theconcentration of slurry 2206 is tested by any suitable means, includingmeasuring refractive index, specific gravity, and/or conductivity. Asdescribed above, temperature may also be measured in order to moreaccurately correlate conductivity/specific gravity/refractive index withthe actual concentration of the chemicals in the slurry. For instance,in some situations, the concentration may be tested by a sensor at thelocation of the mixer 102. In other situations, the actual sensor may belocated apart from the physical location of the mixer 102. For instance,in cold climates, the sensor may be placed in a heated building whilethe mixer 102 is outside, to protect the sensor and associatedprocessing/control equipment.

If slurry 2206 is not concentrated enough, the solutes or slurries 2203,2204, and 2205 will be added to slurry 2206. If slurry 2206 is tooconcentrated, solvents 2201 and/or 2202 will be added to slurry 2206 instep 2207.

Once the desired concentration is reached, as measured by step 2208,slurry 2206 can optionally be released, as indicated by dotted lines inFIG. 22, into one or more holding tanks 2209 and/or other containers2212. Alternatively, the process could continue to produce more ofslurry 2206 until the mixer 102 is full. The quantity of solutiondiverted to holding tank(s) 2209 and/or other container(s) 2212 isdetermined in steps 2210 and 2213. This quantity, along with otherinformation about the product, such as the time of delivery, chemicalsand solvents used, concentration settings, etc. can be recorded in datalog 2211.

The data log 2211 can be used to keep a record of the contents ofholding tank(s) 2209 and/or other container(s) 2212. Also, the data logcould be used to keep track of the quantity of rawsolutes/solvents/chemicals/slurries used. This information could be usedto facilitate order processing of replacement chemicals and supplies.

Although holding tanks and other containers are shown in FIG. 22, thesolution could be released as part of a continuous process. Forinstance, instead of merely filling a discrete number of holding tanksor other containers, the solution could be continuously ornearly-continuously supplied to any receiving vessel, such as a line ofwaiting trucks or another process that uses the solution being produced.

As noted above, the release of slurry 2206 into another vessel isoptional. In some instances, it may be advantageous to operate in awinterization mode. In this mode, the mixer 102 is located outdoors orin a location where it is possible for the ingredients or solution tofreeze. The control panel may be located either outdoors or indoors.When in winterization mode, slurry 2206 may be periodically orcontinuously circulated, even if no solvent or solute is being added.This may help ensure the solution is evenly mixed, help prevent sedimentbuildup, and help prevent any part of the slurry or solution fromfreezing. The continuous mixing also allows conductivity to be moreaccurately measured because the temperature of the solution will be keptmore uniform, and conductivity measurements are dependent on both theconcentration of the solute and the temperature.

Additives

FIG. 23 illustrates three possible processes for mixing an additive intothe solution produced. In FIG. 23A, the volume of the solution isdetermined in step 2301. From this volume, the volume of the additiveneeded is calculated in step 2302. Alternatively, the volume of theadditive can be determined first, and the required volume of solutioncould be calculated from the volume of the additive to be used. Thesolution and additive are combined in step 2303.

FIG. 23B shows the logic required to automate the mixing of an additiveto the solution. First, the total volume (quantity) of the combinationof additive and solution is determined in step 2304. This total volume(for example, the quantity) could be, for example, the volume of thecontainer in which the combination will be placed. That container may bethe same container the solution or additive is in, or it could be athird container 2307. If the volume desired is greater than the totalspace available in container 2307 or the container where the combinationwill be placed, as determined in step 2308, then an alert 2312 will begiven. If mixing were to proceed, the container would overflow.Alternatively, the volume of the combination to be produced could beadjusted below the desired volume, and, assuming no other reasons for analert are present, the process could proceed.

The desired volume of the combination of solution and additive 2304 canbe used to calculate the volume of solution needed and the volume ofadditive needed. If there is not enough of either one, as determined insteps 2309 and 2310, then an alert 2312 must be given. The process couldoptionally proceed by producing a lesser volume than the desired volume2304.

Steps 2309 and 2310, which measure the volume of the solution oradditive, could be carried out by use of a pressure transducer. Thetransducer's sensor would be mounted on the bottom of the vessel. Thepressure reading would be proportional to the weight of the solution oradditive in the column above the transducer's sensor. The volume storedin the vessel could then be calculated using the dimensions of thevessel and the specific gravity of the solution or additive.

Each of steps 2305, 2306, 2307, 2308, 2309, and 2310, which aredescribed above, is optional because any one of steps 2308, 2309, and2310 is enough to trigger an alert. Alternatively, only some of theabove steps may be used in situations where one wants to construct asolution making system using fewer sensors or steps. If an alert istriggered, the process will not be able to produce the desired volume2304 regardless of the outcome of the other steps. If, on the otherhand, there is enough space for the combination, as determined in step2308, and there is enough solution and additive, as determined in steps2309 and 2310, then the desired volume of a combination of solution andadditive will be produced in step 2311.

FIG. 23C shows a logic that mixes an additive with a solution in acontinuous process. Unlike in FIGS. 23A and 2313, a desired volume isnot needed. Instead, the solution is being released without regard tothe final amount to be produced. The flow rate of the solution isdetermined in step 2313. This can be accomplished in many ways. Forexample, the rate at which the flow of solution turns a turbine could bemeasured. Another technique would be to determine the flow rate per atime interval. In this example, a valve being open for 15 seconds at aflow rate of 4 gallons per minute would result in 1 gallon beingdispensed.

Once the flow rate of the solution is known, the flow rate of theadditive needed to create the desired mixture is determined in step2314. In step 2315, the flow rate of the additive is regulated inaccordance with the calculation of step 2314 in order to produce thedesired mixture. Alternatively, the flow rate of the additive could bemeasured, and the flow rate of the solution could be regulated. Or bothcould be regulated in order to achieve a desired flow rate of the finalcombination. A proportional-integral-derivative (PID) circuit, which isknown in the art, could be used to dynamically calculate the requiredflow rate of additive, solution, or both, even if the flow rate is notconstant.

Dispensing

FIG. 24 illustrates the control logic for filling a vessel, such as adrum or a truck which has pulled into a filling station, with thesolution produced by the solution maker. The vessel may be filled fromthe tank used to produce the solution, as in step 2208 of FIG. 22, orfrom a holding tank or other container such as the ones in step 2209 and2212 of FIG. 22. The product is placed into the vessel in step 2401 oncea fill command is received. This could happen once a user presses abutton or once a truck to be filled has pulled onto a weight-sensitiveloading area. Step 2402 shows the flow of the product being delivered tothe vessel being calculated and measured. As described with reference toFIG. 23, the amount of product dispersed, along with any otherinformation about the product that may be useful, can be recorded in adata log in step 2403. For example, if a truck is being filled, the timeand amount of product dispersed could be used to send a bill to thetruck's owner. The product will flow into the vessel to be filled, as instep 2404, until the storage vessel is full (step 2405), a command tostop pumping the product is received (step 2506), or there is no moreproduct to deliver due to lack of supply or any sort of malfunction(step 2407). Once any of the above events are detected, the pumpingstops and the valves are closed (step 2408).

FIG. 25A illustrates the control logic of another aspect of theinvention. This control logic could be used to dispense a desiredquantity of a solution, a mixture (a solution with additives), or both.In step 2501, a desired quantity of the solution or mixture beingproduced is determined. The desired quantity could be entered by a humanoperator, or it could come from an predefined setting, such as a knownsize of a container to be filled. It could also be determinedautomatically or be defined by the requirements of a process thatultimately uses the solution or mixture dispensed.

In step 2502, the quantity of solution or mixture that is alreadyavailable is determined. If this quantity is equal to or greater thanthe quantity to be dispensed, then the desired quantity 2501 isdispensed in step 2506. The volume (or another indicator of quantity)dispensed in step 2506 is recorded into a log or database in step 2507.This log can be used to keep track of a number of aspects of to themachine's operation and can be used to automate auxiliary tasks, asdescribed above with reference to data log 2211. In step 2508, thequantity dispensed is checked. This could be accomplished by measuringthe flow rate, determining the volume of solution or mixture in thevessel into which the solution or mixture is being dispensed (if oneexists), determining the volume of solution or mixture in the vesselfrom which the solution is being dispensed, or any other appropriatemethod. If the desired quantity has not yet been dispensed, then thedispensing and checking continues. Once the desired quantity has beendispensed, then the process is stopped (step 2510).

When the quantity of solution or mixture available is determined in step2502, it is possible that there is not enough solution or mixtureavailable to dispense the desired quantity. In this case, more solutionshould be produced. If the materials are available to produce therequired solution or mixture (step 2504), then that solution or mixturewill be created in step 2505 and dispensed in step 2506.

If there are not enough materials available to produce the amount ofsolution or mixture required (step 2511), then an alert is given in step2512 and the process is stopped (step 2510).

It is possible for steps 2503 (the solution/mixture is available) and2505 (produce solution/mixture) to occur simultaneously: a reservequantity of solution or mixture could be maintained. The reservequantity of the solution or mixture would always either available or inthe process of being replenished during normal operation. Operating inthis manner could increase efficiency by reducing any delay betweenentering a desired quantity and having that quantity dispensed. In thiscase, alert 2512 could be an alert that the desired quantity cannot bedispensed, but it could also be an alert that the desired reserve levelof solution cannot be maintained due to lack of materials.

Finally, while any of the steps described above are performed, themachine can monitor its own functions in step 2513 to detect usage ofmaterials as well as abnormal operation. If a fault is detected (step2514), then the machine could stop dispensing solution to ensure safetyand/or accuracy. As a non-limiting example, a fault could include anunexpectedly high or low level of solution or source materials beingdetected, which would indicate a leak or improper dispensation.

The step of producing a desired solution or mixture for dispensation2505 could include the entire process indicated in FIG. 25A. This couldoccur if a desired quantity of a mixture is to be produced in step 2501.The mixture is a combination of an additive and a solution. In step2505, the mixture would be produced by combining solution and additive.The amount of solution needed to mix with the additive could be viewedas the desired quantity 2501. The process of dispensing the solutioncould therefore be included within step 2505 of the process ofdispensing the mixture.

FIG. 25B is similar to FIG. 25A, but it illustrates that having solutionor mixture pre-made and available is not necessary and does not have tobe provided for. In this aspect of the invention, the quantities ofmaterials needed to make the solution or mixture is checked in step 2515after the desired quantity is entered (step 2501). If there are enoughmaterials available to produce the desired quantity (step 2517), thenthat quantity is produced (step 2505) and dispensed (step 2506). Ifthere are not enough materials available (step 2516), then an alertoccurs (step 2512) and the process is stopped. The design of FIG. 25Bcould be advantageous in situations where having the solution or mixturepre-made is more difficult or costly due to, for example, spaceconstraints.

Finally, while the tank of the present invention is used with a controlsystem that regulates the mixing of chemicals, the tank can be usedseparately from the control system, and the control system can be usedseparately from the tank or in conjunction with a different tank.

Chemicals, Solutions, and Solvents

Various chemicals, solutions, and solvents may be used and created usingaspects of the present invention. Examples include calcium magnesiumacetate, calcium chloride, magnesium chloride, potassium acetate,potassium formate, sodium formate, magnesium acetate, diamoniumphosphate, monoamonium phosphate, urea, ethyl glycol, propylene glycol,and other chemicals.

Modifications

In various aspects, one or more of the structures, systems, methods, andthe like may be used in combination with others. Further, the structureof the solution maker may include additional modifications as follows.First, for example, one or more components of the solution maker may bemade of a non-plastic material. For instance, grate 142 may be made of anon-plastic material, at least in part or in its entirety. Similarly, atleast one of first container 104 and second container 106 may beconstructed at least in part of a non-plastic material. Plastic has anumber of advantages over other materials. Nonetheless, plasticmaterials are not as beneficial as other materials in varioussituations. For instance, plastic materials can become brittle in coldtemperatures or when exposed to various chemicals or ultraviolet light.In this regard, stainless steel, aluminum, or other metals may bebeneficial to use in various environments. In one example, stainlesssteel has the benefit of being highly corrosion resistant where othermaterials would corrode. Alternatively, rubber may be used in place ofplastic materials to enhance the flexibility, resilience, and movementof one or more components of the solution maker 100 and/or associatedlines. Further, one may use concrete or other materials as concrete isboth durable and cost effective.

Second, the water inlets to the solution maker 100 may be simple inletvalves or may be active devices that shift the solvent feed spraypattern to more completely dissolve the chemicals into solution. Forinstance, the inlet valves may have rotating spray patterns, oscillatingspray patterns, and any other spray pattern that prevents unwantedbuildup of the chemical on grate 142. Similarly, the inlet valves forsecond container 106 may similarly be replaced with one or more valvesthat change their spray patterns.

Third, the mixer 102 may be eliminated and replaced with flow controland mixing valves that provide a mixing environment so as to allow thevarious chemicals and solvents to be mixed without the need of a mixingtank.

Fourth, the solution maker 100 may include a modified structure as shownin FIG. 26. FIG. 26 shows a first portion 2601 and a second portion2602. Instead of a permeable grate, the bottom of first portion 2601 isan impermeable layer 2603. A solvent 2609 enters first portion 2601through port 2610. Solvent 2611 next fills portion 2601 as shown asvolume 2611. It is appreciated that port 2610 may be located on any side(including the top and bottom walls) of portion 2601.

The top of portion 2602 is a permeable grate 2604. A chemical to bedissolved in solvent 2609 may be added through one or more sides (oreven a top conduit, not shown) via pathways 2605 and optionally 2607 inthe direction of arrows 2606 and 2608. The chemical to be dissolvedaccumulates on grate 2604 as show as chemical 2612. The solvent 2611next follows conduit 2614 from first portion 2601 into 2602. The solvent2611 is next directed up through grate 2604 or may be sprayed directlybetween grate 2604 and impermeable layer 2603. As chemical 2612dissolves into solvent 2611, the mixture passes through grate 2604 asshown by solution 2616. The solution 2616 may then be further processedas describe herein.

It is appreciated that chemical 2612 may be a solid material, a liquid,or a slurry. For instance, the chemical 2612 may be a salt, a saltsolution, or a liquid chemical (such as ethylene glycol or a fertilizer)that is mixed with a solvent 2611 such as water or other compound intowhich the chemical 2612 dissolves.

Fifth, a further aspect of the mixing system 102 may be modified suchthat no holding tank exists. FIG. 27 shows a mixing system 102 thatlacks a holding tank. A first supply line 2701 provides a concentratedsolution 2703. A second supply line 2702 provides a solvent 2704. Theconcentrated solution 2703 and solvent 2704 are mixed at location 2705.A concentration determination is made at location 2706. The result ofthe concentration determination 2706 controls diverter 2707 such thatmixed solutions of a desired concentration are fed through diverter port2708 and output at 2709. Concentrations that are too high are fedthrough diverter port 2710 and output back to the concentrated supply2703 using optional control valve 2711. Concentrations that are too loware fed through diverter port 2712 and output back to the concentratedsupply 2704 using optional control valve 2713. When a mixture has aconcentration that is too high, feeding the mixture to the concentratedsolution 2703 reduces the concentration of the mixture at point 2705because of the previously added solvent. The result is a decrease in theconcentration at point 2705. Similarly, when a mixture has aconcentration that is too low, feeding the mixture to the solvent 2704increases the concentration of the mixture at point 2705 because of thepreviously added concentrate 2703. The result is an increase in theconcentration of the mixture at point 2705.

Embodiments and Applications

Aspects of the invention may be used in a variety of applications asseparated into the following embodiments.

In a first embodiment, aspects of the invention may be used in acorrosive environment such as mixing brine for deicing applications.Brine used for deicing is very corrosive. Minimizing the number ofdelicate instruments that contact the brine is important. For instance,adding a spinning flow meter in the solution may create severemaintenance problems due to continuous failure of the flow meter. Whileone may use a flow meter for this caustic environment, the cost of theflow meter may be high, thereby making the entire solution maker moreexpensive. One benefit of using this type of flow meter, however, isthat it can provide highly accurate measurements of material flowingpast it.

In a second embodiment, aspects of the invention may be used in otherbrining industries that have less caustic environments. For instance,aspects of the invention may be used in the cheese, beverage, or meatprocessing industries. Here, the food may be dipped in a brine solutionthat has a lower salt level than that of the deicing environment.

In a third embodiment, aspects of the invention may be used inindustrial water supply environments in which large supplies of water orother liquid chemicals need to be mixed before being provided forsubsequent processing or use. For example, hospitals, processing plants,energy generation plants and the like may require large amounts oftreated water Or other materials. Aspects of the present invention maybe used to help mix solutions for these applications.

In a fourth embodiment, aspects of the present invention may be used tomix other chemicals or slurries including but not limited to variousoils, solutions used in water cutting or sand blasting, the productionof blended fertilizers, and milling and the like.

Although the present invention has been described with reference toembodiments, persons skilled in the art will recognize that changes maybe made in form and detail without departing from the spirit and scopeof the invention.

The invention claimed is:
 1. A solution making apparatus that combines asolvent and a chemical comprising: a first container that receives saidsolvent; a second container that receives a solution of said solvent andsaid chemical; a third location that receives a solution of said solventand said chemical; a concentration sensor that outputs a signal; a firstprocessor that determines a concentration of said solution based on saidsignal; a first return conduit that returns said solution from saidsecond container to said first container when a concentration of saidsolution is below a desired concentration; a second return conduit thatreturns said solution from said second container to said third locationwhen a concentration of said solution is above a desired concentration,said second return conduit including an inlet through which additionalsolvent is added to said solution; an outlet conduit that outputs saidsolution having said desired concentration; an additive containerholding an additive; a mixing location at which said additive is mixedwith said solution, wherein the mixing location is selected from thegroup consisting of the additive container, a third container, and aconduit; a controller that determines if said additive and said solutioncan be mixed to one of a desired concentration and desired volume andcontrols a mixing of said additive and said solution to create at leastone of said desired concentration and said desired volume, wherein thecontroller is selected from the group consisting of the first processorand a second processor; wherein said third location is selected from thegroup consisting of the first container and the outlet conduit.
 2. Thesolution making apparatus according to claim 1, further comprising: asensor associated with said additive container, said sensor outputting asignal; wherein said controller uses said signal to determine a volumeof additive in said additive container.
 3. The solution making apparatusaccording to claim 1, further comprising: a sensor associated with asolution container holding said solution, said sensor outputting asignal; wherein said controller uses said signal to determine a volumeof solution in said solution container.
 4. The solution making apparatusaccording to claim 1, further comprising: a sensor associated with anoutput container, said sensor outputting a signal; wherein saidcontroller uses said signal to determine an available volume in saidoutput container to hold the output mixture of said solution and saidadditive.
 5. The solution making apparatus according to claim 1, furthercomprising: a sensor that outputs a signal to said processor, whereinsaid controller uses said signal to determine whether said additive andsaid solution can be mixed to one of a desired concentration and desiredvolume and controls a mixing of said additive and said solution tocreate at least one of said desired concentration and said desiredvolume.
 6. The solution making apparatus according to claim 1, whereinsaid concentration sensor is a conductivity sensor.
 7. The solutionmaking apparatus according to claim 1, wherein said concentration sensoris a specific gravity sensor.
 8. The solution making apparatus accordingto claim 1, wherein said concentration sensor is a refractometer sensor.9. The solution making apparatus according to claim 1, furthercomprising an opening at said first container that receives saidchemical.
 10. The solution making apparatus according to claim 1,further comprising a sump outlet located at the bottom of the secondcontainer.